DSD Information System
Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information >> BRAKE PEDAL (for Gasoline Model) >> Removal [11/2023 - ] >> Procedure

Removal [11/2023 - ]: Procedure

  1. REMOVE BATTERY 

    Refer to REMOVAL [11/2023 - ]

  2. DISCONNECT CONNECTOR 

    See step  15

  3. DRAIN BRAKE FLUID 
    NOTE:

    If brake fluid leaks onto any painted surface, immediately wash it off.

  4. DISCONNECT BRAKE LINE 
    1. Using a union nut wrench, disconnect the 2 brake lines.
      GTY1113744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage or deform the brake lines.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.
  5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 

    Refer to REMOVAL [11/2023 - ]

  6. REMOVE ENGINE STOP AND START SOLENOID FILTER (w/ Stop and Start System) 

    Refer to PROCEDURE - Step 2

  7. REMOVE STOP LIGHT SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 4

  8. REMOVE PUSH ROD PIN 
    1. Remove the clip and push rod pin.
      GTY916662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY 
    1. Disconnect the connector.
      GTY916661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps to separate the wire harness from the brake pedal support assembly.
    3. Remove the bolt and separate the brake pedal support assembly from the instrument panel reinforcement assembly.
      GTY916660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 nuts and push the brake booster with master cylinder toward the engine compartment.
      GTY916659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the brake lines.
      • Do not apply excessive force to the wire harness.
    5. Remove the brake pedal support assembly while avoiding the stud bolts of the brake booster with master cylinder and brake booster support base.
      NOTE:

      Be careful not to deform the bracket of the instrument panel reinforcement assembly.

  10. REMOVE BRAKE PEDAL RETURN SPRING 
    1. Remove the brake pedal return spring from the brake pedal support assembly.
      GTY916658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE STOP LIGHT SWITCH MOUNTING ADJUSTER 
    1. Disengage the 2 claws and remove the stop light switch mounting adjuster.
      GTY916656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE BRAKE PEDAL PAD 
    1. Remove the brake pedal pad from the brake pedal support assembly.
Diesel-Data.com